31% faster order fulfillment for a joinery near Warsaw
We changed the hall layout and introduced a simple barcode system. Production accelerated, and the number of mistakes fell almost to zero.
The Drewno-Styl joinery had a problem with deadlines, due to which it lost regular recipients. We introduced changes in the organization of work, which allowed for producing more furniture without hiring new people.
The challenge
In March 2024, the owner of the company admitted that the average fulfillment time for a custom wardrobe order had grown to 19 business days. Chaos reigned in the 240-square-meter hall – workers lost an average of 43 minutes a day looking for missing formats or fittings. Mistakes when cutting material happened with every ninth order, which generated losses at the level of 4,200 PLN per month. The company faced a choice: either buy a new machine for 85,000 PLN or try to organize what they already have.
Our approach
Instead of buying expensive equipment, the Orzeł Business Strategy team entered the hall for 4 days of observation. We measured the path that each element travels from the saw to the paint shop. It turned out that carpenters unnecessarily walk over a kilometer a day, carrying boards back and forth. In April, we prepared a new plan for the arrangement of machines and assembly stations. Honestly, at first, workers turned up their noses at the changes, so we had to spend two days with them at the tables to show that it actually makes their work easier.
The solution
We rearranged 4 key machines, creating a simple production line – material now flows in one direction and never goes back. We implemented a system of simple barcode labels. Every cut element gets a sticker, thanks to which the assembler immediately knows which customer a given format belongs to. Additionally, we introduced a 'buffer' rack for ready elements, which eliminated stacking plates on the floor. We see it in black and white: order in the hall means fewer nerves and faster work.
Results
Thanks to the changes, the wardrobe production time fell from 19 to 13 business days. The owner resigned from buying a new machine because the current processing power increased by almost one-third.
Timeline
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March 2024Material flow audit and work time measurements
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April 2024Reorganization of machine layout in the hall
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May 2024Training the team in barcode system operation
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June 2024Verification of results and stabilization of processes
"Implementing these codes took 6 days more than we planned because the old printer didn't want to cooperate. But once it started, the difference is visible to the naked eye. Costs fell by a specific amount and finally I don't have calls from angry customers."